Apparatus for producing mottled brick



Aug. 5, 1969 J. R. MURRAY APPARATUS FOR PRODUCING 'MOTTLED BRICK FiledJan. 14, 1966 FIG.3.

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ATTORNEYS United States Patent 3,459,154 APPARATUS FOR PRODUCINGMO'ITLED BRICK James R. Murray, Lakewood, Colo., assignor to LakewoodBrick and Tile Company, Lakewood, (3010., a corporation of ColoradoFiled Jan. 14, 1966, Ser. No. 520,685 Int. Cl. 1305c 11/02 US. Cl.118-102 6 Claims ABSTRACT OF THE DISCLOSURE An apparatus for applyingpowdered coloring agents to a wet ribbon of clay includes a conveyor forthe ribbon and an applicator for the coloring agents spaced from anddisposed transverse to the conveyors. The applicator is spool-shaped andpowder-distributing means on the inner surface of the flanges and outersurface of the connecting cylinder. The cylinder is perforated and isadapted to contain the coloring agent. In normal operation, rotation ofthe applicator releases coloring agents into the distributing meanswhich applies the same to three sides of the moving wet clay ribbon.

This invention relates to the manufacture of brick, and morespecifically, to an apparatus for producing a decorative mottled effecton the exposed face and ends of fired clay building products.

In the manufacture of brick, a composition containing clay, coloringagents and other additives is stirred in a power mixer, extended fromthe mixer in a continuous ribbon having a rectangular cross section, cutinto individual blocks and finally fired in a kiln. Some compositionswhen fired result in a product having different colors or shades of thesame color as a result of the ingredients used, the firing conditions,or both. For example, it is possible to produce a brick by this methodhaving a deep red background color interspersed with areas of blue andpurple. Unfortunately, these conditions are very diflicult to controland the appearance of the resultant product is largely a matter ofchance. Considerable variation occurs from batch to batch and itfrequently becomes necessary to select bricks for uniformity inbackground color. The gradations in color in each brick vary so widelythat it becomes completely impractical to select bricks having similarcolor patterns unless, possibly, for a small job like a planter orfireplace. Also, this method does not result in the production ofcontrasting color pattern, but rather, shadings of the same or similarcolor.

It is possible to produce a design on the face of a brick in acontrasting color by imprinting the exposed surfaces thereof with a dielaid on by a roller or the like prior to firing. The obviousdisadvantage of this technique is that all the bricks look exactly alikeand large areas of the same design are most displeasing from anaesthetic standpoint. Applying a die to the roller and transferring sameto the bricks as a permanent marking also presents some problems.

Ideally, a highly contrasting color should be app-lied to the bricksprior to firing in an entirely random fashion so that no two brickswould be exactly alike. In addition, the coloring matter or dye shouldafford sufficient control so that the colors would be uniform and notleft to chance as is often the case with other techniques.

It has now been found in accordance with the teaching of the instantinvention that the foregoing can, in fact, be achieved by the simple,but unobvious, expedient of feeding the clay ribbon underneath a flangedhollow drum filled with a coloring agent that drops through holes ontosoft, loose, mop-like wipers that slap the exposed clay surfaces in arandom fashion as they move therebetween.

The coloring agent is preferably in a finely divided dry state and aconsiderable number of well-known clay additives with special coloringproperties have been found satisfactory for this purpose. The gentlewiping action of the loosely-engaging mop-like appendages is, in itself,sufficient to turn the drum thus eliminating the need for separate drivemeans. The powder falls on the wet clay issuing from the mixer andadheres thereto long enough to enable the ribbon to be cut intoindividual bricks and fed to the kiln.

It is, therefore, the principal object of the present invention toprovide an apparatus for producing mottled brick.

A second object is the provision of a unique color-distributing drum fordusting powdered coloring agents onto continuously-moving ribbons of wetclay.

Another object is the provision of a coloring apparatus wherebycontrasting colors can be applied in a random pattern to wet claysurfaces prior to firing.

Still another objective of the invention herein disclosed and claimed isto provide a powder-distributing drum with novel mop-like dustingelements for disbursing the powder.

An additional object is to provide apparatus of the type aforementionedthat does not interfere in any way with the conventional brick-makingprocess or require any modification lthereof Further objects are toprovide a brick-mottling apparatus that is inexpensive, completelyautomatic, easy to use, versatile, free of service problems andcompatible with accepted brick-makin g techniques.

Other objects will be in part apparent and in part pointed outspecifically hereinafter in connection with the description of thedrawings that follows, and in which:

FIGURE 1 is a side elevation, somewhat schematic, showing the locationof the mottling apparatus in relation to the extruder and cutter of aconventional brick-making machine;

FIGURE 2 is a section taken along line 2-2 of FIG- URE l to an enlargedscale;

FIGURE 3 is a section taken along line 33 of FIG- URE 2;

FIGURE 4 is a further enlarged fragmentary detail in section showing themanner of attaching one of the moplike dusting elements to a drumflange;

FIGURE 5 is an enlarged fragmentary section revealing one of thepowder-distributing elements fastened to the hub of the drum; and

FIGURE 6 is an end view of the distributing element of FIGURE 5, the hubhaving been shown in section.

Referring now to the drawings for a detailed description of the presentinvention and, initially, to FIGURE 1 for this purpose, referencenumeral 10 represents the hopper of a conventional clay-mixing machinehaving an extruder mechanism 12 at the outlet thereof which extrudes acontinuous ribbon of wet clay 14 through a rectangular orifice or die 16onto a moving belt 18. Belt 18 is reaved around drive and driven rollers20 and 22 of a standard belt conveyor and the intermediateload-supporting areas of the belt run over idlers 24 journalled forrotation between transversely-spaced parallel frame members 26. Belt 18feeds the ribbon of clay 14 to a revolving cutter element 28 which, uponactuation, cuts the ribbon into the individual bricks 30 preparatory todelivering same to the kiln (not shown) for firing.

The foregoing is, of course, standard brick-making equipment and, forthis reason, forms nopart of the present invention. The mottlingapparatus that forms the subject matter hereof has been designated in ageneral way by reference numeral 32 and will be seen to include a hollowflanged rotating drum 34, and axle 36 and a pair of transversely-spacednotched unrights 38 attached to the belt conveyor frame that support thedrum for rotation on belt 18 over the moving wet clay ribbon 14. In theparticular form illustrated, the side-plates 40 have their peripheralmargins resting atop belt 18 which turns the drum clockwise in FIGURE 1as the belt moves to the left. Obviously, the drum can be equipped withan independent source of drive power but there is no reason to do sowhen the frictional contact with the belt answers this need.

Next, with particular reference to FIGURES 2 and 3, it will be seen thatthe drum 34 has a hollow cylindrical hub 42 of a width substantiallygreater than the width of the ribbon of wet clay passing therebeneath.An access opening 44 (FIGURE 3) closed by a coverplate 46 providesaccess to the interior of the hub for the purpose of introducing thepowdered coloring agent therein. Spaced around the entire periphery ofthe hub are a plurality of outlet openings 48 through which the coloringagent 50 passes onto the exterior thereof.

The open ends of the hollow hub 42 are enclosed by the disk-likecircular sideplates 40 which, as shown, are of considerably greaterdiameter than the hub so as to provide continuous annular flanges 44encircling same in spaced-parallel relation to one another andcooperating with said hub to form a general channel-shaped passage 46(FIGURE 2) at the bottom through which the wet clay ribbon passes. Theflanges 44 have a radial dimension selected to support the hub in spacedrelation above the upper surface of the clay ribbon as shown in FIG- URE2 so that the drum lies spaced from both the sides and top surfaces ofthe latter.

Axle 36 is fastened to the sideplates in coaxial relation to the hubwith its ends projecting laterally therebeyond. These projecting axleends float within notches 50 in the upper ends of supporting uprights 38so that the flanges can rid on belt 18. Tubular spacers 52, Washers 54and nuts 56 cooperate with one another and with the axle and uprights 38to maintain the drum centered over the moving ribbon of clay.

Now, the single most important feature of the mottling apparatus of thepresent invention are the mop-like dusting elements 58 that line theannular channel 46 which encircles the drum and which will be describedin detail in connection with FIGURES 2, 3 and 4 to which reference willnow be made. These dusting elements each comprise several strands oftwisted absorbent fibres collected together to form a tuft that isfastened to the exterior surface of the hub and opposed exposed faces ofthe flanges by suitable fasteners such as wires 60. The size of thesetufts is such as to engage th side and top surfaces of the clay ribbon14 as the latter passes through the oversize channel 46 defined by thehub and flanges. The drum is partially filled with a powdered coloringagent which sifts out through the openings 48 in the hub as the drumrotates. Once outside the hub, the powder falls onto the tufted dustingelements and a portion thereof is retained by the latter. Then, as thesedusting elements pass over the top and sides of the clay ribbon, theydischarge some of the powder they hold onto these fresh clay surfaces ina random fashion. The clay is still wet enough at this point to retainmuch of the powder dusted thereon and, for this reason, it sticks evento the vertical sides. Powder-pulf-like dusting elements would functionmuch the same way as the twisted-stand type illustrated except that thelatter has a tendency to flop down upon the clay with a slapping actionthat contributes to the random nature of the powder distribution. Thisis most advantageous for the dusting elements attached to the hub, thoseon the flanges being more compact and somewhat of the powder-puff type.It has been found, for example, that ordinary mop-head twisted fibresfunction quite well as the dusting elements.

In FIGURES 3, 5 and 6, the hub of the drum has been shown equipped withshallow V-shaped deflector elements 4 62 that are mounted on connectors64 that hold same in spaced relation to the hub surface. Thesedeflectors are placed over one or more of the outlet openings 48 andfunction to receive the powder issuing therefrom and distribute it ontothe adjacent dusting elements. As such, they bring about a more evendistribution of the powder although most of the openings 48 are soplaced that they transfer the powder passing therethrough directly toone or more of the dusting elements. Much the same effect could beachieved without the deflectors and they are not, therefore, essentialto operation of the apparatus.

The top of the clay ribbon issuing from the extruder, of course, becomesthe exposed front face of the brick. One end, and sometimes portions ofboth ends may be exposed, so the sides of the ribbon should be coated toprovide for this contingency. On the other hand, the top and bottomfaces of the finished brick are rarely exposed because they contain thestress-relief holes and these surfaces, therefore, require no powder tobe dusted thereon. For this reason, the powder is preferably applied tothe ribbon of clay ahead of the cutting machine that divides it intoindividual bricks. While much the same effect could be obtained byadding the powder to the individual bricks after they were separatedfrom the ribbon, a good deal of the coloring agent would be wasted bydropping into the spaces 66 left therebetween by separating roller 68 asthey leave the cutter on discharge conveyor 70 located adjacent theoutlet of the latter.

In closing, perhaps a few words should be said concerning thecomposition of the coloring agents that are suitable for use inaccordance with the teaching of the instant invention. An excellent andcomprehensive list of well-known clay additives, many of which are usedas coloring agents, can be found in the February 1965 issue of the Brickand Clay Record beginning with chromium oxide on page 45 and continuingthrough to umber on page 60. Most of these additives are in afinely-divided powdered form suitable for insertion into the drum. Oncethe desired contrasting color is decided upon, it is generally a simplematter to select the proper additive or combination thereof which, whenfired in the appropriate oxidizing or reducing atmosphere and at thecorrect temperature, will produce the mottled finished product.

What is claimed is:

1. A device for distributing powdered coloring agents onto the top andsides of a wet clay ribbon continuously extended onto a moving conveyorthrough a rectangular orifice which comprises: a drum having a hollowcylindrical hub of a length greater than the width of the clay ribbonand a plurality of apertures distributed throughout its cylindricalsurface, a pair of circular sideplates of a diameter greater than thehub attached to the opposite open ends of the latter in concentricrelation to produce circumferential flanges that cooperate therewith indefining a continuous annular groove of a depth greater than thethickness of the clay ribbon, means opening into the interior of the hubfor introducing a quantity of a powdered coloring agent, an axleprojecting from both sideplates in coaxial relation to the hub, saidaxle providing means for mounting the drum for rotational movement inposition such that the ribbon of clay passes through the annular groovein spaced relation between the flanges and underneath the hub, andpowderdistributing means fastened to opposed faces of the flanges andthe outer cylindrical surface of the hub in position to receive thepowdered coloring agent dropping through the apertures and dust sameonto the adjacent surfaces of the clay ribbon.

2. The device as set forth in claim 1 in which: the powder-distributingmeans comprises a plurality of moplike cloth fibres formed into tufts.

3. The device as set forth in claim 2 in which: the mop-like tuftsattached to the hub include fibres of a length adapted to slap the topsurface of the clay ribbon as the drum rotates thereover.

4. The device as set forth in claim 1 which includes means operativelyconnected to the drum for rotating same such that thepowder-distributing elements move along with the clay ribbon in the samedirection and at approximately the same speed while dusting the coloringagent thereon.

5. The device as set forth in claim 4 in which: the means for rotatingthe drum comprise vertically-slotted supports adapted to receive theaxle for rotational movement therein and in position such that at leastone of the flanges rides on the moving conveyor carrying the clayribbon.

6. The device as set forth in claim 1 which includes: at least onegenerally V-shaped deflector element attached to the hub in spacedrelation thereto outwardly of some of the apertures, said element beingadapted to intercept the coloring agent passing through the apertures itcovers and disburse same onto the powder-distributing means.

References Cited UNITED STATES PATENTS 454,773 6/ 1891 Schneider 1182672,681,637 6/1954 Simpson 118308 3,238,919 3/1966 Meyer 118308 WALTER A.SCHEEL, Primary Examiner R. I. SMITH, Assistant Examiner US. Cl. X.R.118-109, 267, 308

